QuesTek, a global leader in the field of Integrated Computational Materials Engineering (ICME), has applied ICME technologies in conjunction with its unique Materials by Design®  methodology to optimize alloys (e.g., based on titanium, aluminum, nickel, cobalt, copper, bronze, high strength steel, stainless steel, high entropy alloys, etc.) for various additive manufacturing (AM) processes. Industries of focus include space expoloration, aerospace, automotive, medical, marine and oil and gas.

Additive Manufacturing

High Performance QuesTek Alloys Tailored for AM:

The leading alloys that QuesTek can offer for high performance Additive parts are the following. Please contact QuesTek if you are interested in learning more, or in getting material for your own Additive builds and evaluation.

  • High strength Al designed for AM that combines the processabilty of Al-Si-Mg alloys with the strength of 6061 and 7050 (which are typically prone to cracking during builds). 400 lb powder runs have been produced and characterization is underway. See presentation below for more details.
  • A Ti-6-4 Mod that offers greater strength and toughness vs traditional Ti-6-4, demonstrated via the Sciaky EBAM process with Lockheed Martin. See presentation below for more details.
  • Ferrium® C64® high performance gear steel for rapid prototyping of aerospace gears.

QuesTek's Additive Manufacturing Alloy Design Projects

QuesTek has been involved extensively in multiple alloy and process design and development projects for specific additive manufacturing applications and is looking for potential partners and licensees for further development.

Our direct experience includes successful alloy design on the following via multi year projects:

  • DARPA “Open Manufacturing” project (Honeywell subcontract)

Calibration and validation of models within ICME framework to accurately predict microstructure and properties of Ni 718+ superalloy components produced using DMLS

  • Honeywell Manufacturing Affordability Initiative (MAI) program

ICME development of microstructure and property models for high-temperature Ti- and Ni-based alloys for AM aerospace components

  • QuesTalloy Ti-6-4 Mod Alloy for AM

A Ti-6-4 Mod alloy that offers greater strength and toughness versus traditional Ti-6-4 has been demonstrated via the Sciaky Electron Beam Additive Manufacturing (EBAM) process, in collaboration with Lockheed Martin

  • Computational Design of Aluminum Alloys for AM

Aluminum alloys with improved performance over cast A357 and goals to approach 7xxx series, under two separate U.S. Navy-funded SBIR projects.

  • Exploratory tungsten AM study

Development of a ductile-brittle transition temperature (DBTT) model to acccount for embrittlement in AM tungsten, in partnership with NIU

  • Application of ICME to Optimize Processing of State-of-the-Art Gear Steels in AM (Phase I Army SBIR)

Atomization of Ferrium C64 steel and demonstration of AM builds for aerospace gears

  • ICME Tool Set for Additive Manufacturing of Stainless Steel (Phase I ONR STTR)

Development of an “Integrated Model Toolkit” that enables the modeling of AM process by predicting local composition, microstructure, residual stresses, and mechanical properties for 316L stainless steel aerospace components

  • Quantifying Uncertainty in the Mechanical Performance of Additvely Manufactured Parts Due to Material and Process Variation (Phase I Navy STTR)

Extension of the Accelerated Insertion of Materials (AIM) framework for managing the uncertainty in the mechanical performance of laser power bed AM Ti-6-4 materials

  • Optimized High Performance Stainless Steel Powder for Additive Manufacturing (Phase I Navy SBIR)

Development of a new powder specification for 17-4PH stainless steel, optimized specifically for selective laser melting (SLM) technologies

  • Additive Manufacturing Development of Naval Platform Heat Exchangers (Phase I Navy SBIR)

Creation of new ICME tools and models that will allow for an intelligent selection of appropriate materials for the AM of heat exchange components

Please contact us for more information and we will be happy to discuss your specific materials needs.

QuesTek's ICME approach to designing materials for Additive Manufacturing:

Existing alloy powders and materials used in AM were not optimized for AM processing. The range of alloys to which AM can be applied is currently highly limited and accompanied by significant property sacrifices relative to the baseline (wrought or cast) alloys.

This demands the design of material compositions and resulting microstructures specifically tailored for AM processes.

QuesTek's Materials by Design technology utilizes CALPHAD-based software tools and databases, and process-structure-properties models to design materials that consdiner the unique characterins of AM such as:

  • Rapid solidification - intense residual stresses
  • Non-equilibrium material behavior
  • Significant impurities - poor structural integrity without proper design

Every other manufacturing method has process-specific materials to ensure reliability, AM should as well.

Relevant files

Presentations